Semi-automatic case forming, holding and sealing machine and related order fulfillment system

ABSTRACT

A system for packing items into cases includes a computer system for receiving information regarding items to be packed into a case, the computer system configured to determine a needed case size for loading based upon physical information regarding the items to be packed. A case handling machine includes multiple components that are position-adjustable according to case size to be held, formed and sealed, the case handling machine including a control system including a memory storing a plurality of machine set ups, wherein each machine set up includes data corresponding to positions for the multiple components. The computer system is configured to communicate needed case size information to the case handling machine, wherein the control system of the case handling machine is configured to implement component position adjustment based upon the needed case size information.

TECHNICAL FIELD

This application relates generally to case formers and, more specifically, to a case forming machine and system that facilitates formation and filling of cases of different sizes on an as needed basis.

BACKGROUND

In the packaging industry, products are packed by different type of case formers and case sealers before they are shipped to the consumers. One common type of case former and case sealer is semi-automatic case former and case sealer. This type of case former and sealer needs an operator to unfold the case blanks, use the handle to adjust the conveyors so as to match the case size and put the case between the conveyors to fold the bottom of the case. Similarly, the semi-automatic case sealer also needs an operator to use 2 handles to adjust conveyors to match the case size in order to grip the case sides by the conveyors firmly and another adjustment of the top tape applicator by handle is needed to allow the top tape applicator to touch the top flaps of the case. After the two adjustments, the semi-automatic case sealer is ready to apply adhesive tapes on top and bottom of the case. When different sizes of cases are used, then the operator has to repeat the above-mentioned adjustments again. The problems of this type of semi-automatic case former and case sealer are numerous. Firstly, many adjustments are needed to form different type of cases, which is time consuming. Secondly, the adjustments are carried out by the operator, in other words, the operator may have the chance to adjust it too tight or too loose and finally affect the result of case forming and sealing. Thirdly, if the user wants to avoid adjustment problems, more semi-automatic case formers and case sealers may be needed in order to handle many different sizes of cases, adding undesired cost.

Another type of case former and case sealer is the fully automatic case former and case sealer. This type of machine, to some extent, solve the problem of reliance on the operator to stop the machine to do the adjustments. The fully automatic case former and case sealer uses many sensors to detect and measure the width and height of the cases when they enter the machine.

The problems of this type of fully automatic case former and case sealer are that, first of all, because various sensors are used to detect the case size, it takes time to transmit the information back to the PLC and then get the instruction to adjust the conveyors and top tape applicator. Secondly, the accuracy of sensors may be affected by dust, mis-mounting of the sensors. Thirdly, sensors are more expensive and it makes the price of the fully automatic case former and case sealer higher than the semi-automatic case former and case sealer.

It would be desirable to provide a machine and system that is more readily adaptable to the need to form different size cases in an undefined sequence.

SUMMARY

One objective is to provide a single semi-automatic random case forming, case holding and sealing machine to complete the adjustment of random cases by one single adjustment process without the intervention of the operator manually moving components or using sensors that directly evaluate case size.

In one aspect, a system for packing items into cases includes a computer system for receiving information regarding items to be packed into a case, the computer system configured to determine a needed case size for loading based upon physical information regarding the items to be packed. A case handling machine includes multiple components that are position-adjustable according to case size to be held, formed and sealed, the case handling machine including a control system including a memory storing a plurality of machine set ups, wherein each machine set up includes data corresponding to positions for the multiple components. The computer system is configured to communicate needed case size information to the case handling machine, wherein the control system of the case handling machine is configured to implement component position adjustment based upon the needed case size information.

In another aspect, a method for packing items into a case involves: using a case handling machine including multiple components that are position-adjustable according to case size to be held, formed and sealed, the case handling machine including a control system including a memory storing a plurality of machine set ups, wherein each machine set up corresponds to a respective case size and includes data corresponding to operating positions for the multiple components in order to handle the respective case size; scanning an identifier of a container that contains a plurality of items to be packed; based upon the identifier, a computer system receiving information regarding the plurality of items, including physical information regarding the plurality of items, and the computer system automatically determining a case size to be used for packing the plurality of items based on the physical information; the computer system communicating determined case size data to the case handling machine and the control system of the case handling machine responsively utilizes the stored machine set-up that corresponds to the determined case size to position the multiple components of the case handling machine appropriately for handling the determined case size.

In another aspect, a semi-automatic case handling machine includes a case holding and forming section, including: spaced apart walls that are movable laterally to adapt to different case widths, spaced apart bottom major flap kickers for moving bottom major flaps of a case upward, the bottom major flap kickers movable with the side walls, and a bottom minor flap kicker movable axially to adapt different case lengths. A case sealing section is axially downstream of the case holding and forming section, the case sealing section including: a bottom taper, an upper taper, the upper taper movable vertically to adapt to different case widths, and a pair of spaced apart conveyors for moving cases past the bottom taper and the upper taper for taping, wherein the spaced apart conveyors are movable laterally to adapt to different case widths. An adjustment system includes a memory storing a plurality of machine set ups, wherein each machine set up includes data corresponding to (i) lateral positions for the spaced apart walls, the spaced apart bottom major flap kickers and the spaced apart conveyors, (ii) axial position for the bottom minor flap kicker and (iii) vertical position for the upper taper.

In another aspect, a method is provided of forming, loading and taping a case using a semi-automated case handling machine that includes a plurality of components that are position adjustable based upon case size to be formed, loaded and taped. The method involves: scanning a code associated with a pick tray holding one or more items to be loaded into a case; and automatically moving the plurality of components to respective positions corresponding to a case size associated with the scanned code, in preparation for forming, loading and taping the case.

In a further aspect, a method is provided of forming, loading and taping a case using a semi-automated case handling machine that includes a plurality of components that are position adjustable based upon case size to be formed, loaded and taped. The method involves: inputting a case size code to a controller of the machine; and the controller automatically effecting movement of the plurality of components to respective positions corresponding to a case size associated with the case size code, in preparation for forming, loading and taping the case.

A semi-automatic case forming, case holding and sealing machine includes a case forming device, a case holding device and a case sealing device. The case forming device, case holding device and case sealing device is connected by two devices, one is by the two connection flat plates mounted on the top of the inward or outward conveyors and the parallel conveyors. Another device is by the connection blocks mounted on the two long shafts, the two long shafts are connected with the inward or outward conveyors and the parallel conveyors. Through these two devices, the case forming device connected with the case sealing device to form a single case forming and sealing machine. The characteristic of the semi-automatic case forming and sealing machine is no operator adjustment or sensors are needed to adjust cases size in order to form and seal random cases.

In one embodiment, the semi-automatic case forming, case holding and sealing machine includes a case forming device, a case holding device and a case sealing device. The case forming device composed of a digital code reader holder holding a digital code reader which can be a barcode or QR code reader, mounted at the front of the machine, a PLC mounted at the bottom the case forming device, a case side flaps adjustment device, a bottom flaps adjustment device. The side flaps adjustment device is composed of two inward or outward conveyors and two inward or outward conveyors covers, one horizontal long shaft. The horizontal long shaft is mounted in the horizontal rectangular hollow bar and the horizontal rectangular hollow bar is mounted on the top of the front supporting let with wheel. The two inward or outward conveyors are mounted in the inward or backward conveyors covers. The two inward or outward conveyors move along the horizontal long shaft inward or outward to grasp the sides of the case firmly and at the front of the two inward or backward conveyors covers, two connection flat plates are mounted. The case sealing device is linked with the case forming device by these two connection flat plates.

The case holding device includes two long kicker bars, on each of the long kicker bars, there is a set of kickers mounted. The case holding device is mounted at the bottom of the inward or outward conveyors. After a case is placed in the space created by the inward or outward conveyors and the square hollow metal device in accordance with the case size, the two long kicker bars of the inward or outward conveyors will kick the bottom major flaps of the case to close and the kicker bars will hold the closed position for the operator to fill products into the case.

A bottom flaps adjustment device includes one bottom minor flap kicker, a forward or backward motor, a long shaft mounted with the forward or backward motor and a square hollow metal device. The forward or backward motor is mounted in the rectangular bar, the rectangular bar is mounted at the center position of the case forming device, the forward or backward motor is connected with a long shaft, and this forward and backward motor with long shaft is mounted on a square hollow metal device. At the top of the square hollow metal device, the bottom minor flap kicker is mounted. The forward or backward motor moves the long shaft and the long shaft moves the hollow square metal device and the hollow square metal device will move the bottom minor flap kicker forward or backward based on the various case sizes. In operation, the operator uses the digital code reader to scan the digital code, then the inward or backward conveyors and the square hollow metal device will adjust the case size of the case forming device simultaneously to form a case space that matches the case being used. When the operator opens a folded case and puts it in the case forming device, the bottom minor flaps kicker will bend or fold the bottom minor flaps and the two long kicker bars of the case holding device, which are mounted on the inward or backward conveyors, will kick the bottom major flaps to close and maintain the bottom flaps in a closed position for the operator to fill in products before the case is moved to the case sealing device to seal the bottom and top of the case.

The case sealing device includes an inward or outward case size adjustment device, and a top tape applicator adjustment device. The inward or outward case size adjustment device includes a set of parallel conveyors, two long shafts, one side motor mounted at the side of the case sealing device, and one side motor belt. At the middle of the supporting frame, the side motor is mounted. The side motor is connected with a rectangular plate and the big sprocket is located on the top of the side motor. At the two sides of the front end of the rectangular plate, two sprockets are mounted. The big sprocket is directly controlled by the side motor and links with the side motor belt. In addition, the side motor belt is also connected with the two sprockets. A cover will cover the big sprocket. The action of the side motor will drive the big sprocket and the side motor belt. The side motor belt, which is linked with the two long shafts by the sprockets mounted on the top end of the long shafts, starts to move. The two long shafts are connected with the two parallel conveyors and the inward and outward conveyors. The movement of the side motor controls the inward or outward movement of both the inward or outward conveyors and the parallel conveyors simultaneously.

The top tape applicator adjustment device is composed of one top tape applicator, one top motor, one top motor belt, two vertical shafts, one top tape applicator supporting bar, and one HMI. The top motor drives the top motor belt to move and the top motor belt is linked with the two vertical shafts and the top tape applicator supporting bar is mounted on the two vertical shafts. Finally, the upward or downward movement of the top tape applicator supporting bar controls the upward and downward movement of the top tape applicator based on the case size. One HMI used to enter cases size information is mounted on the top of the top bar and one bottom tape applicator is used to seal the bottom case flaps.

The two parallel conveyors of the case sealing device are connected with two long shafts. When the motor mounted at the side of the case sealing machine moves based on the case size information received, it will drive the side motor belt which is connected with the two long shafts to move and, as the two long shafts are mounted with the two inward or outward conveyors and two parallel conveyors, both the inward or outward conveyors and the parallel conveyors move inward or outward at the same time, controlled by the side motor. In addition, on the top of the two inward or backward conveyors of the case forming device and the parallel conveyors of the case sealing device, two connection flat plates are mounted to connect the two sets of conveyors together. The two connection flat plates help to effect the inward and outward movement of the two sets of conveyors.

At the same time, the top motor controls the top tape applicator movement. The top motor, linked with a top motor belt, drives the top motor belt to move. At the two sides of the top motor belt, two vertical long shafts are connected with the top motor belt, the two vertical long shafts are connected with the top tape applicator by the top tape applicator supporting bar, so the two vertical long shafts will move the top tape applicator downward or upward based on the case size information received. Finally, the whole case size setting is done within one minute by one instruction and no operator is needed to manually adjust the machine.

In another embodiment, no digital code reader is needed. All applicable case sizes are pre-entered into the PLC with the HMI and each applicable case size is assigned a reference number in the HMI. Once the operator decides which case size will be used, the operator just needs to press the case size number on the HMI then the semi-automatic case forming, holding and sealing machine will adjust the machine to match with the case size chosen, and the operator only needs to pick the correct case and put it in the machine to fold and hold the bottom flaps closed for goods to fill in.

The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the semi-automatic case forming, case holding and sealing machine;

FIG. 2 is a side view of the semi-automatic case forming, case holding and sealing machine;

FIG. 3 is a top view of the semi-automatic case forming, case holding and sealing machine;

FIG. 4 is a perspective view of the forward or backward motor;

FIG. 5 is a perspective view of the inward or outward conveyors and the parallel conveyors;

FIG. 6 is a perspective view of the side motor;

FIG. 7 is a perspective view of the side motor and the two long shafts;

FIGS. 8-9 is different view of the mechanism of the forward or backward motor and the side motor;

FIG. 9A is an enlarged view of region 9A of FIG. 9 ;

FIG. 10 is a perspective view of the case sealing device; and

FIGS. 11 and 12 show an order fulfillment system incorporating the semi-automatic case forming, case holding and sealing machine as one part.

DETAILED DESCRIPTION

Referring to FIGS. 1-10 , a perspective view of the semi-automatic case forming, case holding and sealing machine 1 is shown. The semi-automatic case forming, case holding and sealing machine 1 includes case forming device 2, case holding 4 and case sealing device 3. At the front part of the case forming device 2, a barcode reader holder 21 is mounted on the middle of the horizontal hollow rectangular bar 22. Inside the horizontal hollow rectangular bar 22, a horizontal shaft 221 is mounted. The horizontal shaft 221 is used to connect with the two inward or outward conveyors 25 and let the inward or outward conveyors 25 to move along the horizontal shaft 221 smoothly. At the bottom of the horizontal hollow rectangular bar 22, a front supporting leg with wheel 23 is mounted. At the two sides of the horizontal hollow rectangular bar 22, two inward or outward conveyors 25 are mounted. On the two inward or outward conveyors 25, two inward or outward conveyors covers 24 are installed to cover the inward or outward conveyors 25. Below the two inward or outward conveyors 25, two long kicker bars 41 are mounted, and on each of the two long kicker bars 41, there is a set of kickers 42 to kick the bottom major flaps to close and maintain a closed condition. At the middle of the front supporting leg with wheel 23, a rectangular bar 27 is mounted. Inside the rectangular bar 27, a long shaft 28 connected with the forward and backward motor 29 is mounted. On the long shaft 28, a rectangular block with 4 wheels 293 is mounted. This long shaft 28 is connected with a square hollow metal device 291. The rectangular block with 4 wheels 293 is mounted on the square hollow metal device 291. The square hollow metal device 291 is bigger than the rectangular bar 27 and is mounted at the outside of the rectangular bar 27. On the top side of the square hollow metal device 291, a bottom minor flap kicker 292 is mounted.

The case forming device 2 is connected with the case sealing device 3 by two connection flat plates 5. One end of each of the two connection flat plates 5 is mounted on the top side of a respective one of the inward or outward conveyors covers 24 and the other end are mounted on the top side of one of the two parallel conveyors 31. The two parallel conveyors 31 are positioned on the supporting frame 34 and the supporting frame 34 is mounted on the four supporting legs with wheels 32. At the front end and back end of the two parallel conveyors 31, two long shafts 33 are connected with the parallel conveyors 31. On each of the long shaft 33, there are two connection blocks, the connection blocks 332 are used to mount the two inward or outward conveyors 25, and the connection blocks 333 are used to mount the parallel conveyors 31. These connection blocks 332, 333 can move along the long shafts 33. Through the work of the two connection flat plates 5 and the connection blocks 332, 333 mounted on the two long shafts 33, they can cause the inward and outward conveyors 25 and the parallel conveyors 31 to move along the two long shafts 33 and the horizontal shaft 221 at the same time and accomplish the task of adjusting inward and outward conveyors 25 and the parallel conveyors 31 to grasp the case sides firmly.

At the middle of the supporting frame 34, a side motor 35 is mounted. The side motor 35 is connected with a rectangular plate 352 and the big sprocket 353 is located on the top of the side motor 35. At the two sides of the front end of the rectangular plate 352, two sprockets 354 are mounted. The big sprocket 353 is directly controlled by the side motor 35 and are linked with the side motor belt 351. In addition, the side motor belt 351 is also connected with two sprockets 354. A cover 355 covers the big sprocket 353. The action of the side motor 35 will drive the big sprocket and the side motor belt 351. The side motor belt 351 also links with the two long shafts 33 by the sprockets 331 mounted on the top of the long shafts 33. The two long shafts 33 are connected with the two parallel conveyors 31 and the inward and outward conveyors 25. As a result, the movement of the side motor 35 controls the inward or outward movement of both the inward or outward conveyors 25 and the parallel conveyors 31 at the same time. Between the two parallel conveyors 31, a bottom tape applicator 7 is installed. At the two sides of the supporting frame 34, two vertical hollow bars 36 are mounted. Inside the two vertical hollow bars 36, two vertical shafts 361 are mounted and the two vertical shafts 361 are linked with a top tape applicator supporting bar 61. At both ends of the top tape applicator supporting bar 61, there are two plates 611. On the plates 611, each carry 4 wheels 612. These wheels 612 help the top tape applicator supporting bar 61 move along the two vertical shafts 361 upward or downward smoothly. At the center of the top tape applicator supporting bar 61, a top tape applicator 6 is mounted. A top bar 362 is connected on the two ends of the vertical hollow bars 36. At the bottom side of the top bar 362, the top motor 37 is mounted to drive the top motor belt 371 and the top motor belt 371 is connected with the two vertical shafts 361 by the sprocket 363. The top motor 37 is like the side motor 35. The top motor 37 is connected with a rectangular plate 372 and the big sprocket 373 on the top of the top motor 37. At the two sides of the front end of the rectangular plate 372, two sprockets 374 are mounted. The big sprocket 373 directly link with the top motor 37 by the top motor belt 371. The top motor belt 371 is also connected with the two sprockets 374. A cover 375 covers the big sprocket 373. On the top side of the top bar 362, a HMI arm 81 is mounted. The HMI arm 81 is movable, so that the HMI 8 mounted on HMI arm 81 can move based on the need of the operator.

When in work, an operator will use the digital code reader to scan the digital code attached on a pick tray, then the PLC will, based on the pre-stored information for the scanned digital code, instruct the forward and backward motor 29, the side motor 35 and the top motor 37 to adjust the semi-automatic case forming case holding and sealing machine and, in some embodiments, the control of the machine will also output an indication (e.g., visual) to communicate to the operator the case size needed for the items in the pick tray. In detail, the forward and backward motor 29, which is connected with the long shaft 28, will move. This forward and backward motor 29 with long shaft 28 is connected with a square hollow metal device 291. On the top side of the square hollow metal device 291, a bottom minor flap kicker 292 is mounted. The movement of the forward and backward motor 29 causes the movement of square hollow metal device 291 along the long shaft 28 forward or backward. Inside the square hollow metal device 291, a rectangular block with 4 wheels 293 is mounted, which can make the square hollow metal device 291 move smoothly forward or backward. The bottom minor flap kicker 292, mounted on the square hollow metal device 291, is also moved and achieves the adjustment of the case size. At the same time, the side motor 35 also drives the side motor belt 351 to work. The two sides of the side motor belt 351 are linked with the sprockets 331 which are located on the two long shafts 33 and the connection blocks 332, 333 mounted on the two long shafts 33 are also linked with the two inward or outward conveyors 25 and the two parallel conveyors 31. The two parallel conveyors 31 of the case sealing device 3 are connected with the two inward or outward conveyors covers 24 of the case forming device 2 by two connection flat plates 5. Then, the movement of the side motor 35 will finally cause the two inward or outward conveyors 25 and the two parallel conveyors 31 to move inward or outward simultaneously. At the same time, the top motor 37 will drive the top motor belt 371 and the top motor belt 371 is connected with the two sprockets 363 located on the top of the two vertical shafts 361. The two vertical shafts 361 are also connected with the top tape applicator supporting bar 61. As a result, when the two vertical shafts 361 move upward or downward controlled by the top motor 37, the top tape applicator supporting bar 61 also moves upward or downward. As the forward and backward motor 29, the side motor 35 and the top motor 37 receive instructions and work at the same time to adjust the square hollow metal device 291, the inward or backward conveyors 25 and parallel conveyors 31 and the top tape applicator supporting bar 61. The case size adjustment is done within a minute and a case space matched with the adjustment is ready to put the folded case blank in.

FIGS. 2-3 show the side and top view of the semi-automatic case forming, case holding and sealing machine 1. In FIGS. 2 & 3 , at the front end, a barcode reader holder 21 is mounted on the middle of the horizontal hollow rectangular bar 22. At the two sides of the horizontal hollow rectangular bar 22, two inward or outward conveyors covers 24 are mounted. Inside the two inward or outward conveyors covers 24, two inward or outward conveyors 25 (not shown) are installed. Below the two inward or outward conveyors two long kicker bars 41 are mounted and on the long kicker bars 41, two sets of kickers 42 are mounted to kick the bottom major flaps to close and maintain the closed condition. At the middle of the front supporting leg with wheel 23, a rectangular bar 27 is mounted. The square hollow metal device 291 is mounted at the outside of the rectangular bar 27. On the top side of the square hollow metal device 291, a bottom minor flap kicker 292 is mounted. Both the two inward or outward conveyors covers 24 and the two parallel conveyors 31 are connected by the two connection flat plates 5. The two parallel conveyors 31 are mounted on the supporting frame 34 and the supporting frame 34 mounted on the four supporting legs with wheels 32. At the front end and back end of the two parallel conveyors 31, two long shafts 33 are connected with the parallel conveyors 31. At the two sides of the supporting frame 34, two vertical hollow bars 36 are mounted. At the top of the two vertical hollow bars 36, a top bar 362 are mounted. At the bottom side of the top bar 362, the top motor 37 is mounted and on the top side of the top bar 362, a HMI 8 is mounted.

FIG. 4 is a perspective view of the forward or backward motor 29. The forward or backward motor 29 is connected with the long shaft 28 and is mounted in the square hollow metal device 291. On the long shaft 28, a rectangular block with 4 wheels 293 is mounted in the square hollow metal device 291, and causes the square hollow metal device 291 move smoothly along the rectangular bar 27. The square hollow metal device 291 is mounted outside the rectangular bar 27.

FIG. 5 is a perspective view of the inward or outward conveyors and the parallel conveyors. Inside the horizontal hollow rectangular bar 22, a horizontal shaft 221 is mounted. The horizontal shaft 221 is used to connect with the two inward or outward conveyors 25 and the inward or outward conveyors 25 to move along the horizontal shaft 221 smoothly. At the bottom of the inward or outward conveyors 25, the two long kicker bars 41 and two sets of kickers 42 are mounted.

FIG. 6 is a perspective view of the side motor. The side motor 35 is connected with a rectangular plate 352 with the big sprocket 353 located on the top of the side motor 35. At the two sides of the front end of the rectangular plate 352, two sprockets 354 are mounted. The big sprocket 353 is directly controlled by the side motor 35 and link with the side motor belt 351 (not shown in here). In addition, the side motor belt 351 is also connected with the two sprockets 354. A cover 355 covers the big sprocket 353. In operation, the side motor 35 will drive the big sprocket 353, the two sprockets 354 and the side motor belt 351 to rotate. The two ends of the side motor belt 351 are linked with the two sprockets 331 mounted on the two long shafts 33 so the two long shafts 33 are also moved. The movement of the two long shafts 33 will make the two parallel conveyors 31 to move inward or outward because the parallel conveyors are connected with the two long shafts 33.

FIG. 7 is a perspective view of the side motor and the two long shafts. At the front part of the case forming device 2, the front supporting leg with wheel 23 has the horizontal hollow rectangular bar 22 mounted on the top. In this FIG. 7 , no digital code reader holder 21 is installed, all applicable cases size are pre-entered into the PLC with the HMI and each applicable case size is assigned a reference number in the HMI. Once the operator decides what case size is needed, the operator just needs to press the case size number on the HMI, then the semi-automatic case forming, holding and sealing machine will adjust the machine to match with the case size chosen and the operator only needs to pick the correct case and put it in the machine to fold and hold the bottom flaps closed for goods to fill in. At the middle of the front supporting leg with wheel 23, a rectangular bar 27 is mounted. As the square hollow metal device 291 is bigger than the rectangular bar 27, it is mounted outside the rectangular bar 27 with the forward and backward motor 29 and the long shaft 28 mounted inside the rectangular bar 27 (not shown in here). On the top of the square hollow metal device 291, the bottom minor flap kicker 292 is mounted. This square hollow metal device 291 can move smoothly forward or backward along this rectangular bar 27 controlled by the forward and backward motor 29 because inside the square hollow metal device 291, a rectangular block with 4 wheels 293 is mounted. Between the case forming device 2 and case sealing device 3, a rectangular flat plate with “/ \” shape hollow 9 is mounted, which is used for the known bottom flaps kickers 26 to move along the hollow area to adjust the kicking bottom flaps kicking position. At the front side and end side of the case sealing device 3, two long shafts 33 are mounted and parallel to each other. At one end of the two long shafts 33, two sprockets 331 are located. These sprockets 331 are used to connect with the side motor belt 351. On each of the long shaft 33, there are two connection blocks, the connection blocks 332 are used to connect the two inward or outward conveyors 25, and the connection blocks 333 are used to mount with the parallel conveyors 31. These connection blocks 332, 333 can move along the long shafts 33. The two sprockets 331 of the long shafts 33 are linked with the side motor belt 351. Through the work of the two connection flat plates 4 and the connection blocks 332, 333 mounted on the two long shafts 33, they can bring the inward and outward conveyors 25 and the parallel conveyors 31 move along the two long shafts 33 at the same time. The sprockets 331 of the long shafts 33 are connected by the side motor belt 351 to the two sprockets 354 and big sprocket 353 of the side motor 35.

FIG. 8-9 is a different view of the mechanism of the forward or backward motor and the side motor. In FIG. 8 and FIG. 9 , no digital code reader holder is mounted. FIG. 8 is the perspective view of the forward or backward motor 29 and the side motor. In this FIG. 8 , the hollow part of the horizontal hollow rectangular bar 22 permits mounting the horizontal shaft 221. The forward and backward motor 29 with long shaft 28 is connected with a square hollow metal device 291. Inside the square hollow metal device 291, a rectangular block with 5 wheels 293 is mounted to make the movement of the square hollow metal device 291 smooth. The square hollow metal device 291 is bigger than the rectangular bar 27 and is mounted at the outside of the rectangular bar 27. Behind the rectangular flat plate with “/ \” shape hollow 9, two long shafts 33 are mounted and parallel to each other. At one end of the two long shafts 33, two sprockets 331 are located. These sprockets 331 are used to connect with the side motor belt 351 and work with the sprockets 354 and big sprocket 353. Each long shaft 33 includes two connection blocks, the connection blocks 332 are used to connect the two inward or outward conveyors 25, the connection blocks 333 are used to mount with the parallel conveyors 31. These connection blocks 332, 333 can move along the long shafts 33. Through the work of the side motor 35, it will control the movement of the inward or outward conveyors 25 and the parallel conveyors 31. FIG. 9 is the bottom view of the forward or backward motor and the side motor.

FIG. 10 is a perspective view of the case sealing device. The two vertical hollow bars 36 are mounted at the two sides of the supporting frame 34. Inside the two vertical hollow bars 36, two vertical shafts 361 are mounted and the two vertical shafts 361 are linked with a top tape applicator supporting bar 61. At both ends of the top tape applicator supporting bar 61, there are two plates 611. On the plates 611, each carry 4 wheels 612. These wheels 612 help the top tape applicator supporting bar 61 move smoothly along the two vertical shafts 361 upward or downward. At the center of the top tape applicator supporting bar 61, top tape applicator 6 is mounted. A top bar 362 connected two ends of the vertical hollow bars 36. At the bottom side of the top bar 362, the top motor 37 is mounted and the top motor 37 is mounted to drive the top motor belt 371. The top motor belt 371 is connected with the two vertical shafts 361 at the sprocket 363. The top motor 37 is like the side motor 35. The top motor 37 is connected with a rectangular plate 372 and the big sprocket 373 on the top of the top motor 37. At the two sides of the front end of the rectangular plate 372, two sprockets 374 are mounted. The big sprocket 373 directly links with the top motor 37 by the top motor belt 371. The top motor belt 371 is also connected with the two sprockets 374. A cover 375 will cover the big sprocket 373. On the top side of the top bar 362, a HMI arm 81 is mounted. The HMI arm 81 is movable, so that the HMI 8 mounted on HMI arm 81 can move.

Thus, a semi-automatic case forming, holding and sealing machine includes three devices, the first one is the case forming device, the second one is the case holding device and the third one is the case sealing device. Through the cooperation of the three devices, a single semi-automatic random case forming, holding and sealing machine can carry out the work of forming, holding and sealing random size cases without multiple adjustments of both the semi-automatic case former and case sealer by the operator. All the operator needs to do is to put the right case into the case forming device to grasp the side walls of the case, then the case holding device will fold the bottom major flaps, hold the bottom flaps folded case for the operator to fill the bottom flaps folded case with goods. After filling the case, the operator will push the case into the case sealing device to seal both the top and bottom flaps of the case. In one embodiment, semi-automatic case forming, holding and sealing machine has a digital code reader holder mounted at the front of the machine to hold a digital code reader. This digital code reader is one embodiment. The data of random case sizes are pre-entered into the PLC of the semi-automatic case forming and sealing machine (e.g., in memory) before the machine starts to work. Once the digital code reader reads the code (e.g., the scannable code on one of the pick trays T traveling along a tray conveyance path Cl alongside the machine opposite the operator side of the machine), it will trigger the e-commerce software to provide the case size to the PLC and the appropriate light bulb (or other annunciator) A, which may be associated with each case rack CR proximate the operator side of the machine, will flash to indicate which case size is needed (where the different case racks hold different case sizes). The machine will adjust the case forming, holding and sealing devices to match with the selected case size before the machine starts to work.

In embodiments, no digital code reader is needed. All applicable case sizes are pre-entered into the PLC with the HMI and each applicable case size is assigned a reference number in the HMI. Once the operator decides which case size will be used, the operator just needs to press the case size number on the HMI then the semi-automatic case forming, holding and sealing machine will adjust the machine to match with the case size chosen and the operator only needs to pick the correct case and put it in the machine to fold and hold the bottom flaps closed for goods to fill in.

The case forming device includes a case side flaps adjustment device, a bottom flaps adjustment device, a case holding device and a PLC mounted at the bottom of the case forming device. At the bottom of the semi-automatic case forming and sealing machine, a forward or backward motor is connected with a bottom minor flap kicker by a square metal hollow device. The square metal hollow device is mounted on the outside of the rectangular bar. Based on case size information, the forward or backward motor will move the bottom minor flap kicker to move forward or backward to adjust the length of the case size and the holding device includes a two long kicker bars and on the two long kicker bars, two sets of kickers will bend the bottom major flaps and the two sets of kickers will kick the bottom major flaps to close. The case holding device is mounted in the inward or outward conveyors, to close the bottom flaps of different cases and maintain the closed bottom flaps of the case for operator to fill in goods before sending the case to the sealing device to seal the bottom and top of the case. The two inward or outward conveyors are mounted in the two inward or outward conveyor covers. At the front end of the case forming device of the semi-automatic case forming and sealing machine, a case sealing device is connected with the case forming device by two connection flat plates and formed a single semi-automatic random case forming and sealing machine. These two connection flat plates are mounted on the top of the two inward and backward conveyors covers of the case forming device and two parallel conveyors of the case sealing device separately. It makes the two set of conveyors move simultaneously. The movement of the two sets of conveyors is controlled by a side motor mounted at the side of the case sealing device. The case sealing device includes a set of parallel conveyors to grip the two sides of the case, a side motor to control the inward and outward movement of the parallel conveyors and the inward or outward conveyors and one top tape applicator, one bottom tape applicator to seal the top and bottom flaps of the case, one top motor and one HMI.

As used herein, the term controller is intended to broadly encompass any circuit (e.g., solid state, application specific integrated circuit (ASIC), an electronic circuit, a combinational logic circuit, a field programmable gate array (FPGA)), processor(s) (e.g., shared, dedicated, or group—including hardware or software that executes code), software, firmware and/or other components, including the aforementioned PLC and HMI, or a combination of some or all of the above, that carries out the control and/or processing functions of the device or the control and/or processing functions of any component thereof.

Exemplary aspects of the invention include, but are not limited to, the following:

X1. A semi-automatic case forming, case holding and sealing machine includes a case forming device, a case holding device and a case sealing device.

X2. A semi-automatic case forming, case holding and sealing machine as defined in aspect X1 wherein the case forming device includes a digital code reader holder mounted at the front of the machine, a PLC mounted at the bottom of the machine, a digital code reader, a case side flaps adjustment device, a bottom flaps adjustment device.

X3. A case forming device as defined in aspect X2 wherein the case side flaps adjustment device is composed of two inward or outward conveyors, two inward or outward conveyors covers, one horizontal long shaft and two connection flat plates. The horizontal long shaft is mounted in the horizontal rectangular hollow bar and the horizontal rectangular hollow bar is mounted on the top of the front supporting leg with wheel. The two inward or outward conveyors are mounted in the inward or backward conveyors covers. The two inward or outward conveyors are connected with the horizontal long shaft, which is mounted in the horizontal rectangular hallow bar, and move along the horizontal long shaft inward or outward to grasp the sides of the case. At the top front of the two inward or backward conveyors covers, two connection flat plates are mounted. The case sealing device is connected with the case forming device by these two connection flat plates.

X4. A case forming device as defined in aspect X2, wherein the bottom flaps adjustment device includes one bottom minor flap kicker, a forward or backward motor, a long shaft, a square hollow metal device and a rectangular block with 4 wheels. The rectangular block with 4 wheels is located on the long shaft and is mounted in the square hollow metal device. The forward or backward motor is connected with the long shaft. The long shaft is mounted in the square hollow metal device. The forward or backward motor with the long shaft is mounted in the rectangular bar. The rectangular bar is mounted at the center position of the case forming device. At the top of the square hollow metal device, the bottom minor flap kicker is mounted. The forward or backward motor moves the long shaft and the long shaft moves the square hollow metal device as it is connected with the long shaft and the hollow square metal device will move the bottom minor flap kicker forward or backward based on the case size.

X5. A semi-automatic case forming, case holding and sealing machine as defined in aspect X1 wherein the case holding device includes two long kicker bars and two sets of kickers. The case holding device is mounted at the bottom of the inward or outward conveyors. The two sets of kickers mounted on the two long kicker bars can kick the bottom major flaps of a case to close and maintain the closed position.

X6. A semi-automatic case forming, case holding and sealing machine as defined in aspect X1 wherein the case sealing device includes an inward or outward case size adjustment device, a top tape applicator adjustment device.

X7. A case sealing device as defined in aspect X6 wherein the inward or outward case size adjustment device included a set of parallel conveyors, two long shafts, one side motor belt, one side motor. The side motor is mounted at the side of the case sealing device. At the front side and end side of the case sealing device, two long shafts are mounted and parallel to each other.

X8. The inward or outward case size adjustment device as defined in aspect X7 wherein the two long shaft has a sprocket mounted on one end of the long shaft. The sprocket is used to connect with the side motor belt. On each of the long shaft, there are two connection blocks, the connection blocks are used to mount the two inward or outward conveyors and the parallel conveyors.

X9. The inward or outward case size adjustment device defined in aspect X7 wherein the side motor includes a rectangular plate, a big sprocket, two sprockets and a cover. The side motor is connected with a rectangular plate and the big sprocket located on the top of the side motor. At the two sides of the front end of the rectangular plate, two sprockets are mounted. The big sprocket is directly controlled by the side motor and link with the side motor belt. The side motor belt is also connected with the two sprockets. A cover will cover the big sprocket. In operation, the side motor will drive the big sprocket to rotate. The big sprocket is linked with side motor belt. When the side motor belt starts to move, the big sprocket also moves and drives the side motor belt to rotate. The two sprockets are linked with the side motor belt and they also move. The two ends of the side motor belt are linked with the two long shafts by two sprockets so the side motor belt drives the two long shafts to move. The movement of the two long shafts will make the two parallel conveyors and the inward or outward conveyors to move inward or outward.

X10. A case sealing device as defined in aspect X6 wherein the top tape applicator adjustment device is composed of one top tape applicator, one top motor, one top motor belt, two vertical shafts, one top tape applicator supporting bar, one top bar, one HMI. The two vertical hollow bars are mounted at the two sides of the supporting frame. Inside the two vertical hollow bars, two vertical shafts are mounted and the two vertical shafts are linked with a top tape applicator supporting bar. At the center of the top tape applicator supporting bar, top tape applicator is mounted. A top bar connected two ends of the vertical hollow bars. At the bottom side of the top bar, the top motor is mounted to drive the top motor belt. The top motor belt is connected with the two vertical shafts by the sprocket. On the top side of the top bar, a HMI arm is mounted. The HMI arm is movable, so that the HMI mounted on HMI arm can move.

X11. A top tape applicator adjustment device as defined in aspect X10 wherein the top motor is connected with a rectangular plate and the big sprocket is mounted on the top of the top motor. At the two sides of the front end of the rectangular plate, two sprockets are mounted. The big sprocket is directly linked with the top motor by the top motor belt. The top motor belt is also connected with the two sprockets. A cover will cover the big sprocket.

X12. A semi-automatic case forming, case holding and sealing machine includes a case forming device, a case holding device and a case sealing device.

X13. A semi-automatic case forming, case holding and sealing machine as defined in aspect X12 wherein the case forming device include a case side flaps adjustment device, a bottom flaps adjustment device and a PLC mounted at the bottom of the machine.

X14. A case forming device as defined in aspect X13 wherein the case side flaps adjustment device is composed of two inward or outward conveyors, two inward or outward conveyors covers, one horizontal long shaft and two connection flat plates. The horizontal long shaft is mounted in the horizontal rectangular hollow bar and the horizontal rectangular hollow bar is mounted on the top of the front supporting leg with wheel. The two inward or outward conveyors are mounted in the inward or backward conveyors covers. The two inward or outward conveyors are connected with the horizontal long shaft which is mounted in the horizontal rectangular hallow bar, and move along the horizontal long shaft inward or outward to grasp the sides of the case. At the top front of the two inward or backward conveyors covers, two connection flat plates are mounted. The case sealing device is connected with the case forming device by these two connection flat plates.

X15. A case forming device as defined in aspect X13, wherein the bottom flaps adjustment device includes one bottom minor flap kicker, a forward or backward motor, a long shaft, a square hollow metal device and a rectangular block with 4 wheels. The rectangular block with 4 wheels is located on the long shaft and is mounted in the square hollow metal device. The forward or backward motor is connected with the long shaft. The long shaft is mounted in the square hollow metal device. The forward or backward motor with the long shaft is mounted in the rectangular bar. The rectangular bar is mounted at the center position of the case forming device. At the top of the square hollow metal device, the bottom minor kicker is mounted. The forward or backward motor moves the long shaft and the long shaft moves the square hollow metal device as it is connected with the long shaft and the hollow square metal device will move the bottom minor flap kicker forward or backward based on the case size.

X16. A semi-automatic case forming, case holding and sealing machine as defined in aspect X12 wherein the case holding device includes two long kicker bars and two sets of kickers. The case holding device is mounted at the bottom of the inward or outward conveyors. The two sets of kickers mounted on the two long kicker bars can kick the bottom major flaps of a case to close and maintain the closed position.

X17. A semi-automatic case forming, case holding and sealing machine as defined in aspect X12 wherein the case sealing device includes an inward or outward case size adjustment device, a top tape applicator adjustment device.

X18. A case sealing device as defined in aspect X17 wherein the inward or outward case size adjustment device included a set of parallel conveyors, two long shafts, one side motor belt, one side motor. The side motor is mounted at the side of the case sealing device. At the front side and end side of the case sealing device, two long shafts are mounted and parallel to each other.

X19. The inward or outward case size adjustment device as defined in aspect X18 wherein the two long shaft has a sprocket mounted on one end of the long shaft. The sprocket is used to connect with the side motor belt. On each of the long shaft, there are two connection blocks, the connection blocks are used to mount the two inward or outward conveyors and the parallel conveyors.

X20. The inward or outward case size adjustment device defined in aspect X18 wherein the side motor includes a rectangular plate, a big sprocket, two sprockets and a cover. The side motor is connected with a rectangular plate and the big sprocket located on the top of the side motor. At the two sides of the front end of the rectangular plate, two sprockets are mounted. The big sprocket is directly controlled by the side motor and link with the side motor belt. The side motor belt is also connected with the two sprockets. A cover will cover the big sprocket. In operation, the side motor will drive the big sprocket to rotate. The big sprocket is linked with side motor belt. When the side motor belt starts to move, the big sprocket also moves and drives the side motor belt to rotate. The two sprockets are linked with the side motor belt and they also move. The two ends of the side motor belt are linked with the two long shafts by two sprockets so the side motor belt drives the two long shafts to move. The movement of the two long shafts will make the two parallel conveyors and the inward or outward conveyors to move inward or outward.

X21. A case sealing device as defined in aspect X17 wherein the top tape applicator adjustment device is composed of one top tape applicator, one top motor, one top motor belt, two vertical shafts, one top tape applicator supporting bar, one top bar, one HMI. The two vertical hollow bars are mounted at the two sides of the supporting frame. Inside the two vertical hollow bars, two vertical shafts are mounted and the two vertical shafts are linked with a top tape applicator supporting bar. At the center of the top tape applicator supporting bar, top tape applicator is mounted. A top bar connected two ends of the vertical hollow bars. At the bottom side of the top bar, the top motor is mounted to drive the top motor belt. The top motor belt is connected with the two vertical shafts by the sprocket. On the top side of the top bar, a HMI arm is mounted. The HMI arm is movable, so that the HMI mounted on HMI arm can move.

X22. A top tape applicator adjustment device as defined in aspect X21 wherein the top motor is connected with a rectangular plate and the big sprocket is mounted on the top of the top motor. At the two sides of the front end of the rectangular plate, two sprockets are mounted. The big sprocket is directly linked with the top motor by the top motor belt. The top motor belt is also connected with the two sprockets. A cover will cover the big sprocket.

It is to be clearly understood that the above description is intended by way of illustration and example only, is not intended to be taken by way of limitation, and that other changes and modifications are possible.

For example, although the above embodiment contemplates that a scanner is used to scan a code associated with a pick tray holding items to be placed in a case, which code itself incorporates the needed case size information, more automated systems could be implemented. In one such system, per FIGS. 11-12 , a system 200 includes an order fulfillment provider ERP/WMS system 202, which includes HR and Accounting functions, and that receives online orders from an online order system 201, a case packing optimizer computer system 204 and a case handling machine 1.

FIG. 11 shows the process of order fulfillment when an online order is placed in an operation with the a computer system 204 that includes a Case Packing Optimizer software and the case forming and loading machine 1 with automatic changeover for different case sizes. Once the order is received by the ERP/WMS system 202, the order travels through the Enterprise Resource Planning Software (ERP) and Warehouse Management Software (WMS) where it is converted to a pick order 206. When the order picker 208 receives the order, the order picker first scans a tote (or other container) 210 to confirm which tote will be used for receiving the picked order, and the tote identification information for the order is delivered back to the WMS, per 209. The order is then picked based on the item location and quantity of items, which are provided by the WMS as part of the order 206. Once order picking is completed, the picked items placed in the tote 210 are communicated to the WMS, per 209, and the tote is delivered to the packing station 212, per 250, which packing station 212 includes machine 1 and system 204, where the order is packed.

The tote is scanned at 211, and the scanned tote identification is communicated to the Case Packing Optimizer Software (CPOS) 204, which in turn retrieves the order information from the WMS, per 254. Shipping information is also communicated to the CPOS, per 255. The CPOS 204 communicates information regarding the case to be used for packing to the machine 1, per 256, which in turn is communicated to the operator by lighting up the case indicator on the case rack 214, per 260. The tote is also delivered to the machine 1, per 262. The CPOS 204 also communicates case loading details to a pack station monitor 218, per 266, which in turn displays the details so that the operator understands exactly how to load the case. Once the case is loaded, the tote is released from the order, and the release is communicated back to the WMS, per 268. The loaded case is then ready for labeling, and the CPOS communicates, per 270, shipping label information to a shipping label printer 216, which prints the label, which is applied to the packed case 280.

FIG. 12 shows how the Case Packing Optimizer Software (CPOS) of system 204 and the machine 1 are integral to the entire Packing Station process. The CPOS 204 is in charge of getting the order and order item data from the ERP/WMS 202 based on the linked code on the tote 210 (e.g., the tote is scanned at 211, and the tote code sent to system 204, per 252). The CPOS 204 then calculates the optimal case size based on item dimensions, weight, dunnage required and other factors to determine the optimal case to use based on preset, known available case sizes. The CPOS 204 will then send the sizing setup signal to the machine 1, per 256, and in turn the case rack 214, to trigger the appropriate case size change of the machine 1 and to light up the appropriate indicator of the case rack to be used so that the operator selects the proper case size. Furthermore, the CPOS 204 will display instructions on how to pack, what dunnage to use and other packing instructions on the monitor 218 of the machine 1 or a stand-alone monitor near the machine, per 266. This is possible with the machine 1 due to its ability to carry out automatic size changes on a semi-automatic case former and in connection with the CPOS 204 and the case rack 214. The system 204 may also send labeling information to a case labeling system that includes label printer 216.

The operator 290 picks the appropriate case from the case rack, per 291, views the case loading details, per 292, loads the case using the machine 1, per 293.

The CPOS 204 provides advanced algorithms and/or processing that is able to assess the items in the tote, obtain item information from the ERP/WMS 202 (e.g., physical information such as size, shape, weight) and then determines needed case size. The CPOS may also determine or define a correct loading sequence for the items and load orientation for each item, which may also be communicated to the machine 1 interface (or nearby interface) such that an operator receives the proper information for case form and pack. The case size information and loading details are communicated from the CPOS 204 to the machine 1 and/or a nearby information station used by the operator.

With this more advanced solution provided by the system 200, the operator does not need to make any decisions at all such as which case size to use, how to pack a case, what dunnage to use or how to do a size change on a machine. The operator only needs to grab the indicated case, pack the case based on the given instructions and fold the top flaps to send it through for case sealing. 

1. A system for packing items into cases, the system comprising: a case packing optimizer system for receiving information regarding items to be packed into a case, the system configured to determine a needed case size for loading based upon physical information regarding the items to be packed; a semi-automatic case handling machine including multiple components that are position-adjustable according to case size to be held, formed and sealed, the case handling machine including a control system including a memory storing a plurality of machine set ups, wherein each machine set up includes data corresponding to positions for the multiple components; wherein the case packing optimizer system is configured to communicate needed case size information to the case handling machine, wherein the control system of the case handling machine is configured to implement component position adjustment based upon the needed case size information received from the case packing optimizer system.
 2. The system of claim 1, wherein the case packing optimizer system is connected to receive item information from an order fulfillment provider ERP/WMS system.
 3. A method for packing items into a case, the method comprising: using a case handling machine including multiple components that are position-adjustable according to case size to be held, formed and sealed, the case handling machine including a control system including a memory storing a plurality of machine set ups, wherein each machine set up corresponds to a respective case size and includes data corresponding to operating positions for the multiple components in order to handle the respective case size; scanning an identifier of a container that contains a plurality of items to be packed; based upon the identifier, a computer system receiving information regarding the plurality of items, including physical information regarding the plurality of items, and the computer system automatically determining a case size to be used for packing the plurality of items based on the physical information; the computer system communicating determined case size data to the case handling machine and the control system of the case handling machine responsively utilizes the stored machine set-up that corresponds to the determined case size to position the multiple components of the case handling machine appropriately for handling the determined case size.
 4. The method of claim 3, wherein the case handling machine utilizes the determined case size data to trigger an indicator on a case storage device to communicate to an operator which case size should be selected and placed in the case handling machine.
 5. The method of claim 3, further comprising: based on the received information regarding the plurality of items, the computer system automatically determines a case packing procedure and the case packing procedure is communicated to the operator via a display, wherein the case packing procedure includes how to pack the plurality of items and what dunnage to include when packing.
 6. The method of claim 5, further comprising: based upon the identifier, the computer system receiving information regarding shipping of the plurality of items and the computer system communicates shipping label information to a label printer for printing a shipping label to be applied to the packed case. 